Industrial Generator Set Accessories
Generator Set Controller
Decision-Makerr 3500
G6-136 6/18 Page 1
Applicable to the following models:
REZGT and REOZT4 Mobile
REOZK4 and REOZJ4 Stationary
Kohlerr Decision-Makerr 3500 Controller
General Description and Function
The Decision-Makerr 3500 generator set controller provides
advanced control, system monitoring, and system diagnostics
for optimum performance and compatibility.
The Decision-Makerr 3500 controller meets NFPA 110, Level 1
when equipped with the necessary accessories and installed per
NFPA standards.
Controller features
D A digital display and pushbutton/rotary selector dial provide
easy local access to data.
D The controller supports Modbusr protocol. Use with serial
bus or Ethernet networks.
D Integrated hybrid voltage regulator providing 0.5%
regulation.
D Built-in alternator thermal overload protection.
D Encapsulated to protect against dust and dirt with sealed
connectors.
D Isochronous (real and reactive) load sharing with other
Decision-Makerr 3500 controller equipped generator sets.
D Random first-on logic to prevent two or more generator sets
from closing to a dead bus.
D Automatic synchronizer with dead bus closing.
D Soft loading and unloading.
D Integrated Generator Management with Runtime Hour and
Fuel Level Equalization
D Integrated Load Management with six priorities.
Modbusr is a registered trademark of Schneider Electric.
 Annunciator Fault Light
Digital Display Red--Shutdown,
Yellow--Warning

Alarm Horn (located

inside the controller)
Alarm Silence/Lamp Test
Button with Light
Pushbutton/Rotary
Selector Dial

Master Control Buttons

Off/Reset, Auto, Run
Mini USB
with Lights
Communication
Connection

Controller Specifications User Interface Controls and Components

Decision-Makerr 3500 D Backlit LCD digital display with five lines of 35 characters
(see User Interface Displays for menus)
D Power source with circuit protection: 12- or 24-volt DC
D Power drain: 200 milliamps at 24 volts, 400 milliamps at 12 volts D Alarm horn indicates generator set shutdown and warning faults
D Humidity range: 5% to 95% condensing D Environmentally sealed membrane keypad with three master control
D Operating temperature range: --40C to +70C (--40F to +158F) buttons with lights
D Storage temperature range: --40C to +85C (--40F to +185F) d Off/Reset (red)
D Standards: d Auto (green)
d Run (yellow)
d CE Directive
d NFPA 99 D Pushbutton/rotary selector dial for menu navigation
d NFPA 110, Level 1 d Rotate dial to access main menus
d CSA 282-09 d Push dial and rotate to access sub menus
d UL 508 D Annunciator fault light
d ASTM B117 (salt spray test) d System shutdown (red)
D Panel dimensions—W x H, 229 x 160 mm (9.0 x 6.3 in.) d System warning (yellow)
D Alarm silence/lamp test button
NFPA 110 Requirements d Alarm silence
d Lamp test
In order to meet NFPA 110, Level 1 requirements, the generator set D USB and RS-485 connections
controller monitors the engine/generator functions and faults shown d Allows software upgrades
below.[ d Provides access for diagnostics
D Engine functions: d PC communication using SiteTecht
d Overcrank D Dedicated user inputs
d Low coolant temperature warning d Remote emergency stop switch
d High coolant temperature warning d Remote 2-wire start for transfer switch
d High coolant temperature shutdown d Auxiliary shutdown
d Low oil pressure shutdown D Integrated hybrid voltage regulator
d Low oil pressure warning
d High engine speed D Auto-resettable circuit protection mounted on circuit board
d Low fuel (level—diesel or pressure—gas) * D Six programmable isolated resistive sensor analog inputs w
d Low coolant level D Six programmable isolated digital inputs w
d EPS supplying load
d High battery voltage D Three programmable isolated differential voltage analog
d Low battery voltage inputs w
D General functions: D Four programmable relay driver digital outputs w
d Master switch not in auto ] D Two isolated RS-485 ports (Modbusr and PGen)
d Battery charger fault * D One CAN port for optional accessories and/or compatible devices
d Lamp test
d Contacts for local and remote common alarm w The available number of analog and digital inputs/outputs vary by
d Audible alarm silence button generator set model.
* Functions require optional input sensors or kits and are engine Modbusr is a registered trademark of Schneider Electric.
dependent, see Controller Displays as Provided by the Engine ECM.
[ Requires optional RSA for standard NFPA 110 outputs. Paralleling Functions
] Can be disabled for manually operated generator sets.
D Bus sensing
D First on logic
D Synchronizing
D Communication-based isochronous load sharing
D Droop reactive load sharing
D External controlled load sharing via speed and voltage bias signals

G6-136 6/18 Page 2

 Controller Features Controller Functions
D AC Output Voltage Regulator Adjustment. The voltage The following chart shows which functions cause a warning or shutdown.
adjustment provides a maximum of 10% of the system voltage. All functions are available as relay outputs.
D Alarm Silence. The controller can be set up to silence the alarm Warning causes the fault light to show yellow and sounds the alarm horn
horn only when in the AUTO mode for NFPA-110 application or signaling an impending problem.
Always for user convenience.
Shutdown causes the fault light to show red, sounds the alarm horn, and
D Alternator Protection. The controller provides generator set stops the generator set.
overload and short circuit protection matched to each alternator for
the particular voltage/phase configuration. Warning Shutdown
Function Function
D Automatic Restart. The controller automatic restart feature initiates
the start routine and recrank after a failed start attempt. Engine Functions
Critically high fuel level (diesel units) * d
D Common Failure Relay. This relay is integrated on the controller
ECM communication loss D
circuit board. Contacts are rated 2 amps at 32 VDC or 0.5 amp at
120 VAC. ECM diagnostics D D
ECM faults (model/address mismatch) D
D Communication. Controller communication is available via
Engine over speed D[
Ethernet network or serial configuration connection.
Engine under speed D
D Cyclic Cranking. The controller has programmable cyclic cranking. Fuel tank leak (diesel units) * d d
D ECM Diagnostics. The controller displays engine ECM fault code High battery voltage D
descriptions to help in engine troubleshooting. High coolant temperature D D[
D Engine Start Aid. The configurable starting aid feature provides High fuel level (diesel units) * d
customized control for an optional engine starting aid. Low battery voltage D
D Event Logging. The controller keeps a record (up to 1000 entries) Low coolant level D
for warning and shutdown faults. This fault information becomes a Low coolant temperature D
stored record of system events and can be reset. Low cranking voltage D
D Historical Data Logging. Total number of generator set successful Low engine oil level * d d
starts is recorded and displayed. Low fuel level (diesel-powered unit) * d d
D Integrated Hybrid Voltage Regulator. The voltage regulator Low fuel pressure (gas units) * d
provides 0.5% no-load to full-load regulation with three-phase Low oil pressure D D[
sensing. No coolant temperature signal D
D Lamp Test. Press the alarm silence/lamp test button to verify No oil pressure signal D
functionality of the indicator lights. Overcrank D[
D Power Metering. Controller digital display provides voltage, current, Speed sensor fault D
power factor, kW, kVA, and kVAR. General Functions
D Programming Access (USB). Provides software upgrades and Auxiliary inputs (analog or digital) d d
diagnostics with PC software tools. Battery charger fault * D
Common fault (includes [) D
D Remote Reset. The remote reset function supports acknowledging
and resetting faults and allows restarting of the generator set without Common warning D
going to the master control switch off/reset position. Default parameters loaded D
Emergency stop D[
D RSA Remote Monitoring Panel. The controller is compatible with
the Kohlerr Remote Serial Annunciator. File system error (controller firmware) D
Input/output communication loss D
D Run Time Hourmeter. The generator set run time is displayed.
Internal failure D
D Time Delay Engine Cooldown (TDEC). The TDEC provides a time Master switch not in auto D
delay before the generator set shuts down. Metering communication loss D
D Time Delay Engine Start (TDES). The TDES provides a time delay Generator Functions
before the generator set starts. AC sensing loss D D
D Voltage Selection Menu. This menu provides the capability to Alternator protection D
switch the generator output voltage. Requires initial activation using Ground fault input * D
SiteTecht software. NOTE: Generator set output leads may kW overload D
require voltage reconnection.
Locked rotor (failed to crank) D
D Voltage Selector Switch Support. The target voltage and Overfrequency D
alternator protection can be automatically updated based on digital Overvoltage (each phase) D
inputs reflecting position of the voltage selector switch.
Underfrequency D
Undervoltage (each phase) D
(Voltage) regulator comm. loss D
D Standard functions
d Available user functions
* Functions require optional input sensors or kits and are engine
dependent, see Controller Displays as Provided by the Engine ECM.
[ Items included with common fault shutdown

G6-136 6/18 Page 3

 KOHLER CO., Kohler, Wisconsin 53044 USA
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales and service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com

User Interface Displays Decision-Makerr 3500 Available Options

The listing below has D denoting main menus - Fifteen Relay Dry Contacts provide a generator set mounted panel
Metering Menu with up to fifteen relay outputs to signal various customer-provided
devices.
D Generator Metering
D Engine Metering - Float/Equalize Battery Charger available with 6 or 10 amp DC
D Battery Charger Meter volt output. Models are available for NFPA capatibility.
D Overview—Non-Tier Applications (with graphical icons) - Remote Emergency Stop Switch available as a wall mounted
D Overview—Tier IV Applications (with graphical emissions icons) panel to remotely shut down the generator set.
D Paralleling Metering - Remote Monitoring Panel. The Kohlerr Remote Serial
Annunciator (RSA) enables the operator to monitor the status of the
Generator Information Menu
generator set from a remote location, which may be required for
D Generator Information NFPA 99 and NFPA 110 installations.
D Event History
D Generator Configuration Communication and PC Software
D Protection Configuration
D Battery Charger Configuration
Available Options
D Voltage Regulation - Converter, Modbusr/Ethernet. Supports a power system using
D Voltage Selector Switch controllers accessed via the Ethernet. Converter is supplied with an
D Paralleling Operation IP address by the site administrator. Refer to G6-79 for converter
D Emissions Information details.
Controller Configuration Menu - Converter, RS-232/RS-485. Supports a power system using
D Controller Configuration controllers accessed via a serial (RS-232) connection.
D Communication Setup
D Calibration Mobile Paralleling System
Input/Output (I/O) Menu
Refer to G6-148 Mobile Generator Set Paralleling Box
D Analog Resistive Input Setup (GM88594-KP1-QS) for details about the mobile paralleling box features
D Analog Differential Input Setup and benefits.
D Digital Input
- Mobile Paralleling Box allows connection of two Kohlerr mobile
D Digital Output
generator sets to one distribution bus. The paralleling box provides
contactors to connect to and disconnect from the bus, eliminating
Controller Displays as Provided by the Engine ECM the need for motorized breakers for each generator set.
(availability subject to change by the engine manufacturer) Modbusr is a registered trademark of Schneider Electric.
John Deere
Display GM/PSI Kohler KDI (JDEC)
Charge air pressure X X
Charge air temperature X X X
Coolant temperature X X
ECM battery voltage X
ECM fault codes X X
Engine model number X
Engine serial number X
Engine speed X X X
Fuel rate X X X
Fuel temperature X X
Oil pressure X X

DISTRIBUTED BY:

Availability is subject to change without notice. Kohler Co. reserves the

right to change the design or specifications without notice and without any
obligation or liability whatsoever. Contact your local Kohlerr generator
set distributor for availability.  2018 by Kohler Co., All rights reserved.

G6-136 6/18 Page 4